FARO has recently launched the Tracer M Laser Projector. This new solution allows users to reduce the expensive delays associated with the alignment and assembly of large components, help improve process precision, and negate the need for physical templates and hard tooling.
The Tracer M uses Advanced Trajectory Control (ATC) to deliver fast projection. ATC provides superior dynamic accuracy and a rapid refresh rate which minimizes flicker. Photogrammetric targets are used to enable the best fit alignment of the projected image onto the surface or object, thereby allowing the projected image to be consistent with the CAD model.
For larger assemblies and for use in space-constrained areas, multiple Tracer M projectors can be controlled from a single workstation to provide large-scale virtual templates in one coordinate system. The risk of human error and costly scrap during assembly is significantly reduced, in addition, manufacturers are able to avoid the time and expense associated with using large, heavy templates.
FARO, 3D Systems and Canon 3D Printing, will be co-hosting a Scan2Print event on Thursday 4th May 2017.
Taking place at the Canon Open Experience Centre, Uxbridge. the free event’s program will focus on the exciting opportunities delivered by the latest 3D Printing and 3D Scanning technologies, to enhance the efficiency of product design processes.
Real life customer examples will illustrate how informed manufacturers, engineers, and product designers are combining 3D Scanning and 3DPrinting to achieve record levels of productivity, efficiencies, and cost-reductions.
FARO’s advanced 3D solutions enables fully digital workflows by capturing real world geometry for the purposes of empowering design. The company’s advanced technologies allow innovations to be realised, faster design cycles to be completed, and not least, they enable users to become more competitive.
Date: 4th May 2017
Time: 9:30am – 2pm
Location: Canon Open Experience Centre, Uxbridge
Click here to view the Agenda.
The Clackamas Criminal Reconstruction and Forensic Team (CRAFT) is an inter-agency team with one full-time and 18 on-call Reconstructionists. They have traditionally been called in to investigate fatal and serious injury crashes in Clackamas County and to assist with crime-scene investigations. Because fatal crashes were causing lengthy roadway closures, the Clackamas County, Oregon CRAFT team was challenged with limiting road closure time and opening roadways faster. As a result, the team decided to use the FARO Focus3D X 330 scanner as a solution to thier problem.
The capabilities of the laser scanner have allowed for a more flexible approach to utilizing the CRAFT resources on a variety of calls, including those they otherwise had not been able to re-spond to prior to adopting the scanning technology. Criminalist O’Neil commented on how effective the FARO scanner is at capturing crash and crime scenes, “By using the scanner, we spend less time on the scene, we get better data, and we can use a smaller crew. I prefer to have two people to set targets and move the scanner, but, if necessary, I can do it all myself.” O’Neil calculated that using the FARO Focus3D X 330 scanner has saved the Clackamas County Sheriff’s Office (CCSO) more than $28,000 in overtime costs injust 16 months of operation.”
CRAFT is now called out to scan scenes whenever there is an officer-involved shooting, an officer-involved crash, or where a county or city liability may exist. The Focus3D X 330 provides the investigators with a unique ability to accurately verify line of sight issues in a crash or shooting incident. According to Criminalist O’Neil, “In an officer-involved shooting, you can position the view of the point cloud to be at the officer’s eye level. As you move through the cloud, you can see the scene exactly as they saw it.”
FARO measurement technologies have been selected by leading automotive companies to support their production processes in different areas such as research and development, pre-production, production and digital factory & facility management.
In this brief blog post we will give you an overview of the research and development applications, the core of innovation processes and the backbone on which the success of a company in today’s hyper-competitive market depends on.
Clay Studios – CNC Cutter Paths
If the creative act of determining and defining a car‘s form takes place prior to the physical production, clay studios must be used to generate data for CAD and CAM software, and CNC cutter paths for model machining.
Clay studios were one of the first in the automotive industry to implement scanning technology into their day-to-day processes to convert the physical model into CAD, which can then be used as a reference for all further developments.
The configurable FARO optical scanning solutions can easily be moved around the workshop and used to scan the entire surface of the model, quickly collecting all the necessary data for successive processing. Scanned data are also used to generate CNC cutter paths to allow subsequent machining or for reverse engineering.
Using virtual models, designers and bodywork specialists can analyse and compare different design options. Single parts as well as entire sub-assemblies can be assessed in terms of geometry, dimensions and form all in the digital domain.
FARO’s 3D portable measuring systems allow development engineers to move physical samples into the CAD realm to build virtual models for dimensional analysis, computational fluid dynamics (CFD) and finite element analysis (FEA). Virtual design testing can also be completed for failure modes and effects analysis (FMEA) and noise, vibration and harshness (NVH) analysis.
Crash testing is performed to determine the dimensional impact on a vehicle or on some specific components when crashing an object at a given speed. Quality can be a matter of life or death and minimizing the impact of accidents e.g. with the aid of improved safety systems can be decisive for passenger survival.
FARO systems allow users to measure the entire vehicle before and after the crash. A comparison of the two sets of scanned data can then be performed by engineers to analyse and evaluate the dimensional impact of the crash.
Tests may be part of a R&D development cycle as the manufacturers look for ways to improve the quality of passive safety systems such as crumple zones, roll pillars and seat belts. But tests can also be carried out by test centres with the aim of providing objective assessments of component and car safety for OEMs or verifying and certifying that vehicles and parts meet regulatory requirements.
The FARO hardware and software are part of an efficient workflow in order to produce deformation reports or safety certificates with minimal effort.
Benchmarking – Analysis of Competitive Vehicles
The term “benchmarking” has been used to describe the process where one OEM evaluates the products of competitors such as entire vehicles, parts and assemblies. Automakers continue to look for any advantage they can find to stay ahead of their competition.
Rather than taking a select number of measurements on a given part, FARO solutions ensure complete part coverage with the possibility to digitize the entire object surface and generate a 3D CAD model.
FARO’s optical measurement systems allow users to seamlessly scan across diverse surface materials regardless of contrast, reflectivity or part complexity, and to capture intricate components in fine detail. The scan data enables an optimal understanding of the dimensional characteristics of the competitor’s products to be obtained. No time intensive pre-programming for single part capturing is needed.
Despite the availability of design data, companies are still using solid models in original size to analyse the characteristics of vehicles and individual components. The aim of Cubing is to bring parts and components together and evaluate how they fit each other. Once parts are mounted on a structure that replicate and simulate a real configuration, they can be measured and their reciprocal alignment checked and documented.
The solid model is based on a flexible frame with adjustable fixings, allowing a quick configuration of the car parts and components. Cubing inspection with the FARO solutions enables users to detect production issues early on in the development process of a vehicle so that problematic parts can be easily identified. This procedure is also particularly helpful for supplier support.
The process of manufacturing special aftermarket accessories or customized components can benefit by using the FARO measurement systems as an ideal solution for reverse engineering the source vehicles. Design elements to be modified can be scanned using the FARO optical solutions in order to generate the CAD models that will then form the basis of the design activity.
Prototypes can be created, via traditional methods or 3D Printing and then attached to the source item and further checked by using the FARO solution to ensure that they match the CAD design drawings. Further modifications can be made to the physical prototype directly to improve the fit or enhance the design and then measured again to incorporate any changes into the CAD drawing.
Using the FARO augmented reality technology, digitally designed components can be easily compared, in the virtual domain, to real parts or physical mockups for the first design review and to check the fit.
FARO are delighted to announce the launch of the new Vantage Laser Tracker product line. The new FARO® Laser Tracker Vantage product family sets a new price/performance standard for addressing challenges in large-scale metrology including, but not limited to, assembly alignment, part and assembly inspection, machine installation and alignment, and reverse engineering.
The FARO Vantage product family consists of two high performance models, the VantageE with an operating range of 25 meters and the VantageS with an operating range of 80 meters. Both compact models offer industry leading portability with an integrated master control unit (MCU), hot swappable batteries that eliminate the need for AC power and cabling, and industrial grade Wi-Fi for reliable, wireless communications. This set of advanced features, along with a single carrying case, enables easy transport between job sites and/or locations within the factory by a single user.
The FARO VantageS and VantageE Laser Trackers are extremely accurate, portable coordinate measuring machines that enable you to build products, optimize processes, and deliver solutions by measuring quickly, simply and precisely. These Laser Trackers optimize workflow productivity management for large-scale metrology applications including, but not limited to, assembly alignment, part and assembly inspection, machine installation and alignment, and reverse engineering.
You can also view the full Press Release Here.
What is reverse engineering?
Reverse engineering allows the duplication of an existing product, without having the plans, documents or technical details of the product.
In a classical production procedure, the creator creates a detailed plan, in which the production properties of a product are explained. After that, the product goes into production and is built according to that plan.
Reverse engineering follows a reversed method. First, engineers identify the components of a system, as well as finding out how they all relate to one another in order for the system to work. The object is decomposed to ascertain the inner structure, the function of all parts and the way they operate. The making of a duplicate comprises of discovering the physical dimensions, the functionalities and the material qualities of an object.
After that, the moment has arrived to construct a representation of the system analysis with the aid of a computer. The next final entails the reproduction of the original system with extreme accuracy, following the previously laid out plan.
Why do we need reverse engineering?
This is a classical scenario in which reverse engineering is warranted: A company has a machine, but one of the components has broken down, so it needs to be replaced. However, the manufacturer has ceased production of that machine and all of its parts; they don’t supply spare pieces anymore. The owner of the machine can set up a procedure of reverse engineering of the broken piece, rather than having to buy a new machine.
Reverse engineering allows for shorter delays in product development, because this method can rapidly deliver a replacement for a faulty piece, that can be used in a prototype as equipment or in the production process.
However, reverse engineering has a whole array of uses:
How are objects measured in a reverse engineering procedure?
To recreate an object, you have to ascertain the physical dimensions precisely. If you don’t have extremely accurate object measurements, it is possible that the recreated object won’t work because it is not an exact copy of the original.
It is possible to make these very precise measurements manually, with the help of a marking gauge, a micrometre, or other instruments of that type. In modern reverse engineering however, a tridimensional measuring machine is able to determine the geometrics of an object faster and more accurately than any manual measuring device is capable of.
A tridimensional measuring machine measures on three axels, X, Y and Z, and uses a coordinated system in three dimensions. Every axel has a basis, which determines the position of a point on that axel.
Tridimensional measuring machines use feelers to register a point as soon as the instrument comes in contact with the surface of the object that needs to be measured. Each point is measured individually, until the tridimensional measuring machine has collected enough data to allow the software to determine the length, angles and other geometric information of the object. The machine reads the data that enters through the feelers in function of the instructions that the operator has provided. The XYZ-coordinates of each point are then used to ascertain the size and position. A tridimensional measuring machine can measure the dimensions in two different ways: on the hand through direct contact with the object, on the other hand with the help of a laser scanner. The cloud of gathered points is then converted to recreate the surface of the object. This data print is then sent to a computer programme in order for it to be refined, analysed and expanded.
A solution for the digitalisation of a high resolution Arm for reverse engineering: the Design ScanArm combined with Geomagic software.
In order to answer to the needs of the market while designing a product, FARO has developed the Design ScanArm, a new measuring arm combined with a 3D scanner. This innovation is a digital, portable 3D solution made for 3D modelling in designing and the entire managing process, which lasts for the entire product life span.
The FARO Design ScanArm uses modern blue laser technology with an increased digitalisation speed in order to obtain point clouds with a high resolution and to be able to digitalise existing materials without problems, without having to use sprays and other such materials. The apparatus is very light and easy to move, so it can be placed in a lab or study room with ease. The Design ScanArm has a simplified user interface which allows for an easy use, even for users with limited experience or competence in 3D digitalisation.
Due to the combination of the FARO 3D digitalisation and the possibilities of the modelling software by Geomagic, the Design ScanArm offers a key solution that allows its users to digitalise, recreate and modify existing models or test prototypes quickly and with ease. This solution enables users to quickly transfer digitalised data to computer models, that can still be modified. Once the data is received, you can use the modelling functions in different ways, without having to use any other application.
Reverse engineering is an important discipline that can contribute immensely to the life span of machines by enabling the proprietor of the machine to manufacture spare parts at will, even when these are not in production anymore. Reverse engineering also allows for new pieces to be added, to add additional functions or to eliminate errors.
The simplest, fastest, and easiest-to-use tool to measure and create products in the context of a recreating procedure, is a light-weight, portable tridimensional measuring machine. This tool allows you to measure objects with or without contact. The combination of these advantages that the FARO Design ScanArm offers, gives operators a fast and efficient solution in the present work environment and gives them a competitive advantage.
The next generation of automated probes offer advanced in-process inspection for integration and infrastructure at minimal costs.
The FARO Factory Array Imager is a scanner with extremely high accuracy for contactless measurements which, with its blue-light technology measurement, within seconds computes several million 3D coordinates on component surfaces – regardless of colour, texture, reflectance or ambient light.
Structured light and stereo recordings open up new possibilities in 3D measurement & inspection and reverse engineering. The new optical 3D measurement system by FARO, the FARO Factory Array Imager, combines the two processes and complements them with high-performance 3D processing.
The combination of flexibility, portability, speed and accuracy makes the compact and light FARO Factory Array Imager an ideal but cost-effective solution for 3D data capture or reverse engineering of components or modules in many different industries, such as automotive, aviation and space flight, and mechanical and plant engineering.
Okay, so the question is: what exactly is reverse engineering?
Reverse Engineering is the process of duplicating an existing product without the aid of drawings, documentation, or computer models.
Normally the product designer creates a drawing showing how an object is to be built and then the object is manufactured by following the design drawing.
However, with reverse engineering the steps are inverted and the object is ‘reverse engineered’ to discover its structure, function and operation. Therefore, duplication of the part is enabled by capturing physical dimensions, features and material properties.
The FARO ScanArm is a portable CMM ideally suited for reverse engineering applications. One key advantage of using the ScanArm to inspect is that soft, deformable, and complex shapes can be easily inspected without coming into contact with the part, greatly reducing the risk of damaging the item.
Interested in reading more about reverse engineering and success stories with its use? Download the full white paper here!
Quality controls are an essential part of the production process. The producer of exclusive sport cars, Spyker, knows all about it. Each model is made by hand in order to ensure the highest quality vehicle time and time again. And that requires upmost precision and comprehensive quality control.
Thus, Skyper eventually ended up with FARO as a partner. The high accuracy of the FAROArm Prime in combination with it’s ease of use and wide-range meant it was ideal for the in-house inspection Spyker needed to carry out.
The FAROArm Prime delivers the highest FaroArm accuracy at an amazing value. The Prime is the ideal solution for measurements in inspection, reverse engineering, CAD-to-part analysis and for anywhere else a high-accuracy, hard-probing measurement solution is needed.
A skull made of Plexiglas based on a 3D scan…science fiction? Not for the surgeons of the University Medical Centre Hospital in Utrecht, who are using Plexiglas to replace the skull of a woman in desperate need.
The rapid development of 3D-scans and printing is not only opening doors for the manufacturing industry but also are causing a real revolution in the medical world.
The extremely detailed images provided by the 3D scanners lend themselves to a wide range of applications, from plastic surgery to the development of tailor-made prostheses and support for medical research.